Reusable packaging and a method of manufacturing thereof

ABSTRACT

Embodiments of the present invention generally relate to a reusable packaging system and a method of manufacturing a reusable packaging system thereof. The reusable packaging system has a first function of holding consumer products, such as linens, bedding, clothing, and the like, at the point of sale. After the consumer product is removed from the reusable packaging system, the reusable packaging system may be used for a secondary use, such as a plaything for children. The reusable packaging system may be shaped and comprise images to match a theme, such as a castle for princesses or a racecar.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Ser. No. 61/665,671 filed Jun. 28, 2012, entitled “REUSABLE PACKAGING AND A METHOD OF MANUFACTURING THEREOF,” which is incorporated herein by reference in its entirety.

BACKGROUND

1. Field

Embodiments of the present invention relate to a reusable packaging system and a method of manufacturing a reusable packaging system thereof. More specifically, embodiments of the present invention relate to a reusable packaging system having a first function of holding consumer products at the point of sale, and a second use after the product has been removed, such as a plaything for a child, as well as a method of manufacturing such a reusable packaging system thereof.

2. Related Art

Packaging of products is a vital element to the marketing and sale of consumer products, such as linens, bedding, clothing, and the like. Not only does the packaging serve the functional purpose of securely holding or containing the product, and protecting the product from being damaged, the packaging also serves to attract consumers' attention to the product. For many products, the packaging may even cost more than the product itself.

Despite the large amount of resources invested in developing and manufacturing packaging, the consumer rarely keeps the packaging, most often discarding it, as the consumer may destroy the packaging in order to access the product, or just has no secondary use for the packaging.

The packaging may come in various forms, such as cardboard boxes, plastic or vinyl bags, plastic containers, and the like, depending on the consumer product. For example, bedding, such as sheets or comforters, often comes in a vinyl bag. The vinyl bag is normally only functional in holding the bedding and preventing the bedding from getting dirty. The vinyl bag is often transparent, with maybe only a cardboard insert, for example, with the product information on it. As such, there may not be much visual stimulation to attract the attention of consumers. Furthermore, the vinyl bag may only be used to hold or store items, particularly the bedding the vinyl bag originally contains.

Discarding the packaging after the consumer removes the product is a waste of reusable material and an issue given the current state of affairs with disposing of such material to overcrowded landfills.

Today, many children's toys are very complex with many pieces and intricate devices, requiring assembly and some power source. However, children are still often drawn to very simplistic items, such as a piece of paper, a cardboard box or other playthings. However, such packaging items usually are not designed to be used by children, especially as a toy, or plaything and, as explained above, are often disposed of with dire consequences for Mother Earth.

Therefore, a need exists for an attractive, reusable packaging for products, such as bedding, linens, clothes, and the like, that may be reused for a secondary purpose, such as a toy, plaything or children's accessory, after the consumer product has been removed from the packaging, to extend the life and usefulness of the packaging and avoid or at least delay more waste for the planet.

SUMMARY

Embodiments of the present invention generally relate to a reusable packaging system. More specifically, embodiments of the present invention relate to a reusable packaging system having an first function of containing consumer products, such as linens, bedding, clothing, and the like, at the point of sale, and a second use, such as a toy or plaything for a child, as well as a method of manufacturing such a reusable packaging system thereof.

In an embodiment of the present invention, a reusable packaging system is provided. The system comprising packaging shaped and configured to having a first function, for containing consumer product at a point of sale; and a second function, after the consumer product has been removed from the reusable packaging, for use as a plaything. The packaging may include a base; and side portions, extending upward from the base, wherein the base and the side portions form an enclosure, wherein a consumer product may be contained at the point of sale, and wherein, after the consumer product has been removed, the enclosure is used as a plaything.

The packaging may further comprise flaps, extending upward from the upper ends of the side portions, wherein the flaps extend the enclosure upward and are attachable to each other to form a closure at the top of the packaging. The packaging may further include at least one aperture, located at the top of the packaging, sized and configured to form a handle for a user to carry the reusable packaging system.

In another embodiment of the present invention, a method for manufacturing a reusable packaging system is provided. This method includes providing consumer product packaging material; cutting at least a base and side portions from the packaging material; applying indicia on at least one of the side portions; cutting perforations into at least one of the side portions to provide access to the interior of the reusable packaging; and assembling the base and the side portions to form a reusable packaging enclosure, whereby the assembled enclosure is a plaything. The method of may further comprise the step of forming an aperture at the top of the enclosure for use as a handle.

BRIEF DESCRIPTION OF THE DRAWINGS

So the manner in which the above recited features of the present invention may be understood in detail, a more particular description of embodiments of the present invention, briefly summarized above, may be had by reference to embodiments, several of which are illustrated in the appended drawings.

Figures in the appended drawings, like the detailed description, are examples. As such, the figures and the detailed description are not to be considered limiting, and other equally effective examples are possible and likely. Furthermore, like reference numerals in the figures indicate like elements, and wherein:

FIGS. 1 and 2 are perspective view drawings of a reusable packaging system in accordance with one embodiment of the present invention; and

FIG. 3 is a plan view drawing of the reusable packaging system of FIGS. 1 and 2 in an unassembled state in accordance with one embodiment of the present invention;

FIG. 4 is a plan view drawing of the reusable packaging system of FIGS. 1 and 2 in an unassembled state in accordance with one embodiment of the present invention; and

FIG. 5 is a flow diagram illustrating an exemplary method in accordance with one embodiment of the present invention.

The headings used herein are for organizational purposes only and are not meant to be used to limit the scope of the description or the claims. As used throughout this application, the word “may” is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Similarly, the words “include,” “including,” and “includes” mean including but not limited to.

DETAILED DESCRIPTION

In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of embodiments or other examples described herein. In some instances, well-known methods, procedures, components and circuits have not been described in detail, so as to not obscure the following description.

Further, the examples disclosed are for exemplary purposes only and other examples may be employed in lieu of, or in combination with, the examples disclosed. It should also be noted the examples presented herein should not be construed as limiting of the scope of embodiments of the present disclosure, as other equally effective examples are possible and likely.

FIGS. 1 and 2 depict different perspective view drawings of a reusable packaging system 100 in accordance with an embodiment of the present invention. The reusable packaging system 100 comprises enclosure portions described as a front wall 102, side walls 104 and 106, a back wall 108, and a base 110. While FIGS. 1 and 2 depict four walls, it should be appreciated that more or less than four walls is contemplated by embodiments of the present invention. Alternatively, instead of walls, reusable packaging system 100 may have a hemispherical or semi-elliptical shape such that it comprises just one enclosure surface and a base. Alternatively, reusable packaging 100 may have a spherical or elliptical shape such that it comprises just one enclosure surface with no definable base. The shape of reusable packaging system 100 may be any other regular or irregular shape, as long as it is able to enclose, hold or contain the consumer product, such as, for example, bedding, linens, clothes, and the like.

Reusable packaging system 100 may further comprise a front flap 103, side flaps 105 and 107, and a back flap 109 extending upwardly from the respective side walls. The flaps serve to provide the top portion of the enclosure for the product. As depicted in FIGS. 1 and 2, flaps 103, 105, 107 and 109 may be configured to resemble a roof of a house or castle, as explained hereinafter. Flaps 105 and 107 may each comprise a slot 113 and 114 through which a protrusion on either flaps 103 and 109 may penetrate in order to interconnect the flaps and achieve a secure enclosure. It should be appreciated that any means to connect or interconnect the flaps known to a person of ordinary skill in the art is contemplated. For example, instead of a mechanical, folding or friction fit means, the flaps may be connected using adhesive or hook and loop fastening means, and the like. Alternatively, reusable packaging system 100 may comprise as few as one flap, or a top surface, where at least one of walls 102, 104, 106 and 108 may be configured such that the one flap may securely interconnect with at least one of the walls 102, 104, 106 and 108 to provide an enclosure for the product.

Reusable packaging system 100 may further comprise a handle 112. Handle 112 may extend from at least one of flaps 103, 105, 107 and 109. Alternatively, reusable packaging system 100 may have slots or apertures, not pictured, in any of walls 102, 104, 106 and 108, and/or any of flaps 103, 105, 107 and 109 to serve as handles. In such an embodiment, the slots or apertures may generally be in at least two opposite walls or flaps. For example, the slots or apertures may be in side walls 104 and 106.

Walls 102, 104, 106 and 108, flaps 103, 105, 107 and 109, and handle 112 may be made of any material strong enough to hold a consumer product, such as bedding, linens or clothes, and sturdy and rigid enough such that the reusable packaging system may maintain its shape without the product being contained within and durable to be used as a plaything after the product has been removed. The material may also be light enough such that reusable packaging system 100 does not add a substantial weight to the overall consumer product, and may still be able to be lifted without the use of any extraneous devices or machinery. Such material may include, but not be limited to, cardboard, composite material, plastic, lightweight wood, such as balsa wood, and the like, or any combination thereof.

The walls and flaps of reusable packaging system 100 may have indicia such as pictures or other visuals, in addition to the product information, printed on top, or the sides or the bottom or any combination thereof. For example, to appeal to children, such as young girls, reusable packaging system 100 may have princess characters and a castle design, to go along with the configuration of reusable packaging system 100 as explained above and depicted in FIGS. 1 and 2. Any character or design may be printed on reusable packaging system 100, to appeal to boys and/or girls. The character and/or design, together with the configuration and/or shape of reusable packaging system 100, may also be suited to match a specific theme, such as the castle shape and design of reusable packaging system 100 and the princess characters, along with the consumer product itself. For example, the consumer product may be of the same princess theme as the reusable packaging. As another example, reusable packaging system 100 may be shaped as a car, with car designs and/or characters on the packaging as well as on the consumer product contained within. The walls and flaps of reusable packaging system 100 may further comprise protrusions, stickers, sequins, or any other design elements to further the theme and appeal to the secondary user of reusable packaging system 100, such as children.

The walls and flaps of reusable packaging system 100 may further comprise apertures 115. In addition to potentially serving as handles, as described above, apertures 115 may further the secondary use of reusable packaging system 100 as a toy or plaything, for example. In one embodiment, where reusable packaging system 100 is used as a castle as described above, apertures 115 may act as windows. Apertures 115 may be pre-cut in reusable packaging system 100. The apertures may also serve as openings for consumers to see, touch and feel the consumer product at the point of sale, adding to the buying experience.

Alternatively, apertures 115 may have perforations so they may be easily punched out after the product has been removed. There may be any number of apertures 115, in any shape or size, which may fit on reusable packaging system 100 without minimizing its effectiveness as a package. Reusable packaging system may alternatively have no apertures.

The size of reusable packaging system 100 may vary depending upon the consumer product to be contained within reusable packaging system 100, as well as the secondary use of reusable packaging system 100. At a minimum, reusable packaging system 100 should be able to contain the consumer product, such as bedding, linens or clothing. Where reusable packaging system 100 has a secondary use as a castle, in accordance with the example above, reusable packaging system 100 may be configured to be the size of a doll house, where a child could place dolls, figurines, and the like inside. In the same scenario, reusable packaging system 100 may be sized to fit at least one child inside, where reusable packaging system 100 may serve as an actual castle or fort within which the child may play. The range of sizes from small, for dolls, figurines, action figures, and the like, to large, for children, may apply to whatever theme is applied to reusable packaging system 100. It should be appreciated the size of reusable packaging system 100 may be even larger, as long as the large size does not negatively affect its primary purpose as a product packaging system.

FIGS. 3 and 4 are plan view drawings of reusable packaging system 100 in alternative unassembled states in accordance with embodiments of the present invention. Both configurations depict reusable packaging system 100 (walls 102, 104, 106 and 108, base 110, flaps 103, 105, 107 and 109, handle 112, and slots 113 and 114) as being manufactured from one piece of material. It should be appreciated any other configuration known to a person of ordinary skill in the art, where reusable packaging system 100 may be formed from one piece of material, or several pieces of material, is contemplated.

In FIGS. 3 and 4, the dashed lines represent the separation of each surface, specifically where the material is to be folded or creased in order to achieve the final configuration of reusable packaging system 100. At these locations, reusable packaging system 100 may have a partial incision or single-sided perforation to assist in the folding of the material.

After the material is folded as such, the walls and flaps may be securely attached to each other by any means known to a person of ordinary skill in the art and as described herein. For example, they may be glued to each other with any adhesive known to a person of ordinary skill in the art. As another example, each wall and/or flap may have male and female parts such that they can interconnect with each other. They may also attached using hook and loop fastening material.

In an alternative embodiment, each wall and/or flap may be cut as separate pieces and individually attached to its adjacent pieces by any means known to a person of ordinary skill in the art, as discussed herein.

FIG. 5 depicts a flowchart of a method 500 for manufacturing a reusable packaging system in accordance with another embodiment of the present invention. While method 500 references reusable packaging system 100, as depicted in FIGS. 1 and 2 and described herein, it should be appreciated method 500 may be implemented to manufacture any reusable packaging system in accordance with other embodiments of the present invention. Method 500 may begin at process block 502. After block 502, method 500 may then proceed to process block 504.

At process block 504, a packaging material is provided. The material may be any material described hereinabove with respect to the material utilized in previously-described embodiments of the present invention, including but not limited to, cardboard, plastic, lightweight wood, and the like. After process block 504, method 500 may proceed to process block 506.

At process block 506, a panel is cut from the material. Where reusable packaging system 100 is made of one piece in accordance with an embodiment, the shape of the panel may take on the shapes depicted in FIGS. 3 and 4, or any other shape or configuration where reusable packaging system 100 may be formed from one piece of material. In embodiments where each wall and/or flap is to be its own individual piece, step 506 may be repeated until all the necessary pieces are cut out. The shapes of these panels may be rectangular, as for the walls of the embodiment depicted in FIGS. 1 and 2, trapezoidal for the flaps, or any other shape, such as polygonal, circular, and freeform shape, as required for other embodiments. In accordance with embodiments of the present invention, the first panel may be cut by hand, machine, mechanical device, or any other feasible means for cutting a panel from a length of material. After step 506, method 500 may proceed to process block 508.

At process block 508, indicia such as the images to be placed on the face of reusable packaging system 100 are applied to the walls and/or flaps. In one embodiment, this may be done by printing the images directly on the panel or panels cut out at process block 506. In another embodiment, the images may be first printed on a sheet of paper or other printable surface, and then applied to the panel or panels using any adhesive known to a person of ordinary skill in the art. This may be done by having one printed sheet for each wall and/or flap. Alternatively, the printed sheet may be one sheet, similar to unassembled reusable packaging system 100 as depicted in FIGS. 3 and 4, and applied to reusable packaging system all at once. This may be done before or after assembly of reusable packaging system, as described hereinafter at process block 512. After process block 508, method 500 may proceed to step 510.

At process block 510, perforations for apertures to be used for the first or secondary use of reusable packaging system 100 are applied to reusable packaging system 100. Process block 510 is optional, as reusable packaging system 100 may include no apertures. Furthermore, this may be done before or after process block 508. After process block 510, method 500 may proceed to process block 512.

At process block 512, the panel or panels cut out at process block 506 are assembled and attached to each other to form the final configuration of reusable packaging system 100. Where there is only one panel, such as depicted in FIGS. 3 and 4, this requires first providing incisions or one-sided perforations at the folding points of the singular panel that separate the walls and flaps. Then, the singular piece is folded at these locations.

Finally, the walls are attached to each other and/or the base by any interconnection means known to a person of ordinary skill in the art, as described herein. Where each wall, flap, and base may be cut out as individual panels, only this last step is necessary. After process block 512, method 500 terminates at termination block 514.

In alternative embodiments of the present invention, prior to proceeding to the termination block 514, the method 500 may proceed to providing the consumer product, such as a piece of bedding material, and placing the product into assembled reusable packaging system 100. Then, reusable packaging system 100 may be closed via the flaps, or by any other means known to a person of ordinary skill in the art for enclosing the product in accordance with embodiments of the present invention.

While the foregoing is directed to embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. In particular, it should be appreciated that any element of any embodiments disclosed herein may be combined with any other elements from any other embodiments disclosed herein, in accordance with yet further embodiments of the present invention. 

What is claimed is:
 1. A reusable packaging system, comprising: packaging shaped and configured to having, a first function, for containing consumer product at a point of sale; and a second function, after the consumer product has been removed from the reusable packaging, for use as a plaything.
 2. The reusable packaging system of claim 1, wherein the packaging comprises: a base; and side portions, extending upward from the base, wherein the base and the side portions form an enclosure, wherein a consumer product may be contained at the point of sale, and wherein, after the consumer product has been removed, the enclosure is used as a plaything.
 3. The reusable packaging system of claim 2, wherein the packaging further comprises flaps, extending upward from the upper ends of the side portions, wherein the flaps extend the enclosure upward and are attachable to each other to form a closure at the top of the packaging.
 4. The reusable packaging system of claim 3, further comprising at least one aperture, located at the top of the packaging, sized and configured to form a handle for a user to carry the reusable packaging system.
 5. The reusable packaging system of claim 4, wherein the handle aperture is formed within one or more flaps.
 6. The reusable packaging system of claim 2, further comprising indicia on the outside of the packaging.
 7. The reusable packaging system of claim 6, wherein the indicia comprise images applied to at least one surface.
 8. The reusable packaging system of claim 7, wherein the images have a common theme with the consumer product contained therein.
 9. The reusable packaging system of claim 2, wherein the packaging comprises a shape of a child-friendly theme.
 10. The reusable packaging system of claim 9, wherein the child-friendly theme is selected from a group consisting of: a castle, a racecar, a fort, and a house.
 11. The reusable packaging system of claim 2, further comprising perforated sections on at least one side portion, such that the inside of the reusable packaging system may be easily accessible.
 12. A method for manufacturing a reusable packaging system, comprising: providing consumer product packaging material; cutting at least a base and side portions from the packaging material; applying indicia on at least one of the side portions; cutting perforations into at least one of the side portions to provide access to the interior of the reusable packaging; and assembling the base and the side portions to form a reusable packaging enclosure, whereby the assembled enclosure is a plaything.
 13. The method of claim 12, further comprising the step of forming an aperture at the top of the enclosure for use as a handle. 